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Abstract:

A titanium diboride target contains fractions of one or more metals from
the group including iron, nickel, cobalt and chromium as well as carbon.
The mean grain size of TiB2 grains is between 1 μm and 20 μm,
the carbon content is in a range of 0.1 to 5% by weight and the total
content of Fe, Ni, Co and/or Cr is in a range of 500 to 3,000 μg/g.
The carbon is distributed in free form at the grain boundaries of the
TiB2 grains in such a way that mean distances between individual
carbon particles are less than 20 μm. The porosity is less than 5% by
volume.

Claims:

1-6. (canceled)

7. A titanium diboride target for physical vapor deposition, the titanium
diboride target comprising: fractions of one or more metals selected from
the group consisting of iron, nickel, cobalt, chromium and carbon;
TiB2 grains with an average grain size of between 1 μm and 20
μm; a carbon content in a range from 0.1% to 5% by weight; a total
content of Fe, Ni, Co and/or Cr in a range from 500 to 3,000 μg/g; at
least part of the carbon being distributed in free form at grain
boundaries of the TiB2 grains; and a porosity of less than 5% by
volume.

8. The titanium diboride target according to claim 7, wherein the carbon
content is in a range from 0.5% to 3% by weight.

9. The titanium diboride target according to claim 7, wherein the average
grain size of the TiB2 grains is between 2 μm and 10 μm.

10. The titanium diboride target according to claim 7, which comprises an
Fe content in a range from 1,000 to 2,000 μg/g.

11. The titanium diboride target according to claim 7, which comprises
defining average distances between individual carbon particles of less
than 20 μm.

12. A method for producing a titanium diboride target, the method
comprising the following steps: grinding a starting powder mixture of
TiB2 powder and graphite powder in a grinding assembly with grinding
beads containing one or more metals selected from the group consisting of
Fe, Ni, Co and Cr until a total amount of Fe, Ni, Co and/or Cr is in a
range from 500 to 3,000 μg/g; and compacting the fully ground powder
mixture by hot pressing at a pressing pressure in a range from 10 MPa to
40 MPa and at a temperature in a range from 1,600.degree. C. to
2,000.degree. C., to produce the titanium diboride target according to
claim 7.

13. A method for producing a titanium diboride target, the method
comprising the following steps: grinding a starting powder mixture of
TiB2 powder and graphite powder in an attritor with iron grinding
beads until an iron content is in a range from 1,000 to 2,000 μg/g;
and compacting the ground powder mixture by hot pressing at a pressing
pressure in a range from 25 to 35 MPa and at a temperature in a range of
1,600.degree. C. to 1,850.degree. C., to produce the titanium diboride
target according to claim 10.

Description:

[0001] The invention relates to a titanium diboride target for physical
vapor deposition that comprises fractions of one or more metals from the
group consisting of iron, nickel, cobalt, and chromium, and also
comprises carbon.

[0002] PVD (physical vapor deposition) processes are coating processes
wherein the coating is generated by physical means, by evaporation of the
coat-forming particles from a target, condensation of the vapor, and coat
formation on the substrate to be coated.

[0003] In view of the lower coating temperature and the generally lower
process costs by comparison with CVD (chemical vapor deposition)
processes, PVD processes are being used increasingly also for the
production of hard material coats on tools for machine cutting or on
wearing parts.

[0004] Among the various PVD processes, particular significance in
practice has been acquired more particularly by cathode sputtering
processes, in which the target is atomized by ion bombardment and
converted to the vapor phase, or by ARC-PVD processes, where atoms and
ions are converted to the vapor phase from the evaporation source by
electrical discharge in the form of an arc load.

[0005] The target here is always the source of the material to be
evaporated, and is then installed into the coating unit directly or via a
cathode mount, depending on the nature of the PVD process. For the
ARC-PVD process, in particular, temperature distribution is very often
improved by providing the targets with a cooling plate on their reverse,
this plate either being in form-fitting contact with the target, with
effective thermal conduction, or else being joined fusionally to the
target, by means of a suitable bonding process.

[0006] The ARC-PVD process has the advantage over the cathode sputtering
process that higher ionization rates and also higher deposition rates are
achieved.

[0007] The process, as a result, becomes more economical, process control
is improved, and, as a result of the higher energetic growth conditions,
it becomes possible to exert a positive influence on the coat structure.

[0008] Titanium diboride coats, which are used frequently, on account of
their high hardness and, in particular, good wear resistance, as hard
material coats which come into contact with nonferrous metals, however,
are very difficult to produce by means of ARC-PVD processes. The thermal
shock resistance of titanium diboride is low. Since the arc of light in
the ARC-PVD process means that the target can be evaporated only within
very narrowly confined spatial and temporal zones, these properties of
titanium diboride result in large thermal stresses, as a result of which
the target may be prematurely destroyed.

[0009] The literature reference "Ceramic cathodes for arc-physical vapour
deposition: development and application", O. Knotek, F. Loffler, Surface
and coating technology 49 (1991), pages 263 to 267, describes the
production of titanium diboride ARC targets by HIPing (hot isostatic
pressing) of pure titanium diboride powders, which are provided with less
than 1% by weight of various metallic additions such as aluminum and
nickel and also metalloid additions such as boron and carbon, and also
the production of titanium diboride coats using these ARC evaporation
sources.

[0010] Among the conclusions from the experiments it is said in particular
that the application of the HIP (hot isostatic pressing) process is
important for the production of titanium diboride targets, in order to
allow coatings to be produced by the ARC-PVD process.

[0011] The titanium diboride targets produced in this way, however, still
do not have the necessary thermal shock resistance that would be needed
for an ARC-PVD coating process to function smoothly in practice.

[0012] It is an object of the present invention, therefore, to provide a
titanium diboride target which can be used without problems in practice
for the ARC coating process as well.

[0013] In accordance with the invention, this is achieved in that the
average grain size of the titanium diboride grains is between 1 μm and
20 μm, the carbon content is in a range from 0.1% to 5% by weight, the
total amount of iron, nickel, cobalt and/or chromium is in the range from
500 to 3000 μg/g, and the carbon is distributed in free form at the
grain boundaries of the titanium diboride grains such that the average
distances between the individual carbon particles are less than 20 μm,
and in that the porosity is less than 5% by volume.

[0014] It is important here that at least one of the stated metallic
components is present within the stated range, it also being possible, of
course, for further, low-melting metallic components to be present, such
as copper or aluminum, but they never on their own obtain the desired
effect.

[0015] The average grain size of the titanium diboride grains is
determined by the laser diffraction process.

[0016] It is particularly advantageous here if the carbon content is in a
range from 0.5% to 3% by weight, iron is present as metallic component in
the range from 1000 to 2000 μg/g, and the average grain size of the
TiB2 grains is between 2 μm and 10 μm.

[0017] By virtue of the present invention it has been found that, by means
of a completely uniform carbon distribution and distribution of the
metallic additions within the stated ranges, titanium diboride targets
are produced which can be vaporized without problems even by the ARC-PVD
process, without thermal stresses causing local or complete
disintegration of the target.

[0018] This is achieved in that a starting powder mixture of TiB2
powder and graphite powder is ground in a grinding assembly with grinding
beads which comprise one or more metals from the group consisting of Fe,
Ni, Co, and Cr until the total amount of Fe, Ni, Co and/or Cr is in the
range from 500 to 3000 μg/g, and in that the compaction of the fully
ground powder mixture takes place by hot pressing, at a pressing pressure
in the range from 10 MPa to 40 MPa and at a temperature in the range from
1600° C. to 2000° C.

[0019] It is important here that the metallic fractions are not added as
powder, but are instead introduced merely as abraded material via the
grinding beads which comprise at least one of the listed metals.

[0020] The method is particularly advantageous when the starting powder
mixture of TiB2 powder and graphite powder is ground in an attritor
with iron grinding beads until the iron content is in the range from 500
to 3000 μg/g, and the compaction of the ground powder mixture takes
place by hot pressing, at a pressing pressure in the range from 25 to 35
MPa and at a temperature in the range from 1650° C. and
1850° C.

[0021] The grinding operation serves essentially for uniform distribution
of the carbon and of the metallic components. Customary grinding times
with which the metallic additions are brought within the specified range
are situated within an order of magnitude of 10 to 120 minutes, depending
on the type of mill used. Particularly rapid incorporation is achieved
through the use of an attritor as the mill.

[0022] Another very decisive factor for the production of the targets is
that the compaction of the fully ground powder mixture is accomplished
not by an HIP process but instead by hot pressing within the stated
pressing pressures and temperatures. As a result of this there is no need
for the containment of the starting powder mixture, as is necessary with
the HIP process for the application of the isostatic pressing pressure,
with the result that the process becomes more cost-effective and in
particular that internal stresses in the compacted target are avoided; in
the case of the HIP process, owing to the very different thermal
expansion coefficients of containment material and titanium diboride,
such stresses would occur.

[0023] For the purposes of the present invention, the term "hot pressing"
is to include all variant forms of hot pressing, with or without direct
current transit, such as, for example, the SPS (spark plasma sintering)
process or the FAST (field assisted sintering technology) process.

[0024] The invention is illustrated below with reference to production
examples and figures.

EXAMPLE 1

[0025] For purposes of experimentation, a roundel-shaped target with a
diameter of 60 mm and a thickness of 8 mm was produced in accordance with
the invention.

[0026] The starting material used was a titanium diboride powder having a
boron content of 30.88% by weight, an iron content of 0.023% by weight, a
carbon content of 0.020% by weight, the remainder being titanium, and an
average grain size d50 of 2.39 μm.

[0027] In a pot mixer, 1980 g of this titanium diboride powder were ground
for 2 hours, with addition of 20 g of graphite and 2000 g of isopropanol,
using 8000 g of steel balls having a diameter of 15 mm. The powder
mixture was subsequently dried by evaporation of the alcohol. Chemical
analysis gave an iron content of 0.154% by weight, corresponding to 1540
μg/g, and a carbon content of 1.0% by weight in the powder mixture.

[0028] The powder mixture was subsequently compacted in a hot press, using
graphite tools, with a maximum pressing pressure of 30 MPa and a maximum
temperature of 1830° C., for a holding time of 40 minutes, to give
a roundel having a diameter of 60 mm and a thickness of 8 mm.

[0029] As a result of the hot pressing, a density of the material of 4.4
g/cm3 was reached, corresponding to 98% of the theoretical density.

[0030] FIG. 1 shows the scanning electron micrograph of the microstructure
of a fracture surface of a target of the invention at 2500 times
magnification.

[0031] Clearly visible from the micrograph are the dark-colored, lamellar
graphite particles at the grain boundaries of the TiB2 grains, with
average distances from one another in the order of magnitude of 10 μm.
Additionally visible is the high density of the microstructure, with a
very low porosity.

EXAMPLE 2

[0032] For purposes of comparison, a target was produced having the same
dimensions as in Example 1, with similar production parameters, but not
in accordance with the invention--without addition of carbon.

[0033] The starting material used was a titanium diboride powder having a
boron content of 31.71% by weight, an iron content of 0.032% by weight, a
carbon content of 0.044% by weight, the remainder being titanium, and an
average grain size d50 of 4.48 μm.

[0034] In a pot mixer, 200 g of this titanium diboride powder were ground
for 3 hours, with addition of 200 g of isopropanol, using 800 g of steel
balls having a diameter of 15 mm.

[0035] The powder was subsequently dried by evaporation of the alcohol.
Chemical analysis gave an iron content of 0.119% by weight, corresponding
to 1190 μg/g, and a carbon content of 0.050% by weight.

[0036] The powder was subsequently compacted in a hot press, with a
maximum pressing pressure of 30 MPa and a maximum temperature of
1800° C., for a holding time of 20 minutes.

[0037] As a result of the hot pressing, a density of the material of 4.4
g/cm3 was reached, corresponding to 98% of the theoretical density.

EXAMPLE 3

[0038] For purposes of comparison, two targets were produced having the
same dimensions as in Example 1, with similar production parameters, but
not in accordance with the invention--without addition of carbon and
without grinding of the starting powder.

[0039] The starting material used was a titanium diboride powder having a
boron content of 31.4% by weight, an iron content of 0.028% by weight, a
carbon content of 0.042% by weight, the remainder being titanium, and an
average grain size d50 of 3.81 μm.

[0040] The starting powder was subsequently compacted in a hot press, once
with a maximum pressure of 30 MPa and a maximum temperature of
1800° C., with a holding time of 60 minutes, and once with a
maximum pressing pressure of 30 MPa and a maximum temperature of
2200° C., with a holding time of 30 minutes.

[0041] In the first case, the hot pressing produced a target having a
density of the material of 3.3 g/cm3, corresponding to 73% of the
theoretical density, and in the second case a target having a density of
the material of 3.4 g/cm3 was attained, corresponding to 76% of the
theoretical density.

[0042] For comparative experiments, the targets produced according to
Examples 1 and 2 were installed into a molybdenum cathode holder with a
graphite sheet for thermal contacting.

[0043] The corresponding cathodes were then investigated for their
behavior in an ARC-PVD unit, with the following coating parameters:

[0044] ARC current 60-70 A

[0045] voltage 21 V

[0046] chamber temperature
24° C.

[0047] operating pressure 1.5 Pa argon.

[0048] On account of their low density, the targets produced according to
Example 3 were destroyed while still being machined for installation into
the cathode holder, and could therefore not be used.

[0049] In a 60-minute operation, the target produced in accordance with
the invention, according to Example 1, behaved stably. The target showed
no cracks at all and exhibited a smooth surface depleted in thickness by
1 to 2 mm.

[0050] The target produced not in accordance with the invention, according
to Example 2, had cracked after just a few minutes of operation, and
shortly thereafter was completely destroyed.

[0051] The targets produced according to comparative examples 2 and 3 show
clearly that not only the addition of carbon but also the uniform
distribution of small fractions of iron, which are introduced into the
starting powder exclusively through the abraded material during grinding,
are necessary in order to ensure good functionality of the targets.

[0052] The invention is by no means limited to the production examples
described. Thus, in particular, targets are also included which have been
unified fusionally by a bonding process with a cooling plate made, for
example, of molybdenum.